Drive plate assembly for hybrid module

Abstract

The hybrid module includes a rotor carrier. The hybrid module further includes a rotor segment supported by the rotor carrier. The hybrid module further includes a torque converter, the torque converter having an impeller, the impeller having an impeller shell fixed to the rotor carrier. The impeller shell and the rotor carrier define a housing therebetween. The torque converter further includes a turbine, the turbine having a turbine shell in fluid communication with the impeller shell. The turbine is disposed within the housing. The hybrid module further includes a drive plate assembly disposed outside the housing. The drive plate assembly includes an inner drive plate fixed to the rotor carrier. The drive plate assembly further includes an outer drive plate fixed to the inner drive plate and configured to receive torque.

Description

Technical Field

[0001] Cross - Reference to Related Applications This application claims priority to U.S. Non - Provisional Application No. 17 / 876,602, filed Jul. 29, 2022, the entire disclosure of which is incorporated herein by reference.

[0002] Technical Field The present disclosure generally relates to hybrid modules, and more specifically, to a drive plate assembly for a hybrid module.

Background Art

[0003] Hybrid modules are generally known. Often, packaging and / or fitting all desired components, such as an e - motor, a crank damper, a torque converter, a torque converter clutch, a disconnect clutch, and a resolver, within a hybrid module architecture is difficult due to axial and radial constraints. Additionally, magnetizing the rotor segment of an e - motor after assembling the torque converter is difficult due to limitations in the gap between the drive plate and the rotor segment. The lack of sufficient clearance for the magnetizing tool to access the rotor segment can result in insufficient magnetization of the rotor segment, which can degrade the performance of the e - motor.

Summary of the Invention

Means for Solving the Problems

[0004] Embodiments disclosed herein provide a hybrid module comprising a rotor carrier, rotor segments supported by the rotor carrier, a torque converter, and a drive plate assembly. The torque converter includes an impeller, the impeller having an impeller shell fixed to the rotor carrier. The impeller shell and the rotor carrier define a housing between them. The torque converter further includes a turbine, the turbine having a turbine shell in fluid communication with the impeller shell. The turbine is disposed within the housing. The drive plate assembly is disposed outside the housing. The drive plate assembly includes an inner drive plate fixed to the rotor carrier. The drive plate assembly further includes an outer drive plate fixed to the inner drive plate and configured to receive torque.

[0005] In the embodiment, the outer drive plate may extend radially outward from the outer surface of the rotor segment. In the embodiment, the inner drive plate may be disposed radially inward from the outer surface of the rotor segment. In the embodiment, the outer drive plate may be fixed to the inner drive plate radially inward from the outer surface of the rotor segment. In the embodiment, the outer drive plate may be fixed to the inner drive plate via a weld. The weld may be located radially inward from the outer surface of the rotor segment.

[0006] In the embodiment, the outer drive plate may be fixed to the inner drive plate via a connector. The connector may be located radially inward from the outer surface of the rotor segment. The hybrid module may include a flex plate. The outer drive plate may be axially disposed between the rotor segment and the flex plate. The outer drive plate may be fixed to the flex plate radially outward from the connector. The flex plate may include a window aligned radially and circumferentially with the connector. The connector may extend into the window.

[0007] In the embodiment, the inner drive plate may be fixed to the rotor carrier radially inward of the outer drive plate. In the embodiment, the hybrid module may include a stud configured to receive torque. The stud may be supported by the outer drive plate and disposed at its radially outer end. The outer drive plate may be fixed to the inner drive plate radially inward of the stud.

[0008] Embodiments of the present disclosure further provide a method for assembling a drive plate assembly into a hybrid module having a rotor carrier, rotor segments supported by the rotor carrier, and a torque converter. The method includes securing the inner drive plate of the drive plate assembly to the rotor carrier. The method further includes mounting the rotor segments to the rotor carrier. The method further includes mounting the impeller shell of the torque converter to the rotor carrier. The method further includes securing the outer drive plate of the drive plate assembly to the inner drive plate after the rotor segments have been magnetized.

[0009] In embodiments, the outer drive plate may be fixed to the inner drive plate via a weld. In embodiments, the inner drive plate may be positioned radially inward from the outer surface of the rotor segment. The outer drive plate may extend radially outward from the outer surface of the rotor segment. In embodiments, the outer drive plate may be fixed to the inner drive plate via a connector. The method may further include aligning a window in the flex plate with the connector. The method may further include fixing the flex plate to the outer drive plate via a stud. In embodiments, the outer drive plate may be fixed to the inner drive plate radially inward from the outer surface of the rotor segment. In embodiments, the method may further include fixing the outer drive plate to the flex plate via a stud. [Brief explanation of the drawing]

[0010] [Figure 1]This shows a cross-sectional view of the upper half of a hybrid module, including a drive plate assembly, according to one embodiment of the present disclosure. [Figure 2] A cross-sectional view of the upper half of a hybrid module, including a drive plate assembly, according to an alternative embodiment of the present disclosure is shown. [Figure 3] An illustrative flowchart of an exemplary process for assembling a hybrid module, including a drive plate assembly, according to embodiments of this disclosure is provided. [Modes for carrying out the invention]

[0011] Embodiments of the Disclosure are described herein. It should be understood that similar drawing numbers appearing in different drawings identify identical or functionally similar structural elements. It should also be understood that the disclosed embodiments are merely examples, and other embodiments may take various alternative forms. The drawings are not necessarily to scale, and some features may be exaggerated or minimized to illustrate details of specific components. Therefore, the specific structural and functional details disclosed herein should not be construed as limiting, but merely as representative criteria for teaching those skilled in the art to use the embodiments in various ways. As those skilled in the art will understand, various features illustrated and described with reference to any one of the drawings can be combined with features illustrated in one or more other drawings to create embodiments not expressly illustrated or described. Combinations of illustrated features provide representative embodiments for typical applications. However, various combinations and modifications of features consistent with the teachings of the Disclosure may be desired for specific applications or implementations.

[0012] The terms used herein are for the sole purpose of describing specific aspects and are not intended to limit the scope of this disclosure. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as those generally understood by those skilled in the art to which this disclosure pertains. Any method, device, or material similar or equivalent to those described herein may be used in the implementation or testing of this disclosure, but the following exemplary methods, devices, and materials are described herein.

[0013] Typically, hybrid vehicles, which combine a battery-powered e-motor with an automatic transmission driven by an internal combustion engine, have limited available space. A hybrid module includes a rotor segment that requires magnetization of the e-motor supported by a rotor carrier, and a drive plate fixed to the rotor carrier and configured to receive torque from a flex plate connected to the internal combustion engine. It is desirable to magnetize the rotor segment after assembly of the torque converter to the rotor carrier, for example, to reduce the risk of contamination of the rotor segment via fragments that could be attracted to the magnetized rotor segment, and to maintain ease of assembly by avoiding the introduction of magnetic force from the rotor segment that would need to be overcome during assembly of the rotor segment into the hybrid module. Additionally, it is desirable to fix the drive plate to the rotor carrier before assembly of the torque converter, for example, via rivets, in a manner that prevents fluid leakage from the rotor carrier. Therefore, the drive plate is assembled into the hybrid module before the rotor segment is magnetized. The drive plate limits the available clearance for the magnetization tool to reach the rotor segment.

[0014] Embodiments of the present disclosure provide a hybrid module including a drive plate assembly having an inner drive plate fixed to a rotor carrier and an outer drive plate fixed to the inner drive plate. The two-piece drive plate assembly allows the outer drive plate to be assembled to the inner drive plate after the rotor segments have been magnetized, thereby increasing the clearance for the magnetization tool to magnetize the rotor segments.

[0015] Figure 1 shows a cross-sectional view of the upper half of a hybrid module 100 according to one embodiment of the present disclosure. The hybrid module 100 includes a rotor assembly 102 and a stator assembly 104, which form an e-motor assembly. The rotor assembly 102 includes a rotor carrier 106, rotor segments 108, end rings 110, spring end plates 112 and 114. The rotor carrier 106 includes an axially extending portion 116 and a radially extending portion 118. The rotor segments 108 are mounted on the outer surface of the axially extending portion 116 of the rotor carrier 106. For example, the rotor segments 108 may be stacked segments. The spring end plates 112 and 114 are assembled on both axial sides of the rotor segments 108. Specifically, the spring end plate 112 is axially positioned between the rotor segment 108 and the end ring 110, and the spring end plate 114 is axially positioned between the rotor segment 108 and the radially extending portion 118. The end ring 110 is configured to compress the spring end plates 112 and 114 to clamp and / or secure the rotor segment 108 to the rotor carrier 106 in order to transmit frictional torque between the rotor segment 108 and the rotor carrier 106. Once the desired compression force is achieved, the end ring 110 is fixed to the rotor carrier 106, for example, by welding.

[0016] The stator assembly 104 is positioned radially outward from the rotor assembly 102 and is fixed to the bell housing 120 for the transmission. The stator assembly 104 includes a stator carrier 122, stator segments 124, and a water jacket 126. The stator segments 124 may be, for example, stacked stator segments and are mounted on the inner surface of the stator carrier 122, for example, by shrink-fitting. In other words, the stator carrier 122 is heated to expand its inner surface, and the stator segments 124 are placed on top of it. Once the stator carrier 122 has cooled, its inner surface is shrink-fitted to the stator segments 124. The water jacket 126 is fixed to the stator carrier 122 and encloses a shield chamber 128 between them.

[0017] The hybrid module 100 further includes a torque converter 142 comprising a turbine 144 having a turbine shell 146 and at least one blade mounted thereon, and an impeller 148 having an impeller shell 150 and at least one blade mounted thereon. For example, the impeller shell 150 is fixed to the rotor carrier 106 at a weld 152. The impeller shell 150 and the rotor carrier 106 define a housing or enclosure for the torque converter 142.

[0018] The torque converter 142 is axially positioned between the impeller 148 and the turbine 144 and may include a stator 158 to improve the efficiency of the torque converter 142 by redirecting the fluid flowing from the blades of the turbine 144 before it reaches the impeller 148. For example, the impeller 148 blades push the fluid outward as they rotate around the axis of rotation AR. The fluid pushes the turbine 144 of the torque converter 142, causing the turbine 144 to rotate around the axis of rotation AR. The stator 158 functions to return the fluid from the turbine 144 to the impeller 148 with minimal or no power loss. The driving force is transmitted from the turbine 144 to the transmission input shaft (unnumbered).

[0019] The torque converter 142 further includes a lock-up clutch 154 and a damper 156. The lock-up clutch 154 and damper 156 are housed within a housing defined by the impeller shell 150 and the rotor carrier 106. The lock-up clutch 154 includes a piston 160 and clutch plates 162 for transmitting torque between the rotor carrier 106 and the damper 156. The damper 156 may include a spring 164, cover plates 166, 168 radially connected to each other outside the spring 164, and an output section 170. Cover plate 166 may be connected to at least one of the clutch plates 162, and cover plate 168 may be connected to the turbine shell 146. That is, cover plates 166, 168 are arranged to act as inputs to the damper 156. Torque is transmitted from the damper 156 to the transmission input shaft.

[0020] The torque converter 142 further includes an impeller hub 172 connected to the inner end of the impeller shell 150, for example, by welding. The impeller hub 172 extends axially away from the impeller shell 150. The torque converter 142 further includes a resolver assembly 174 having a resolver rotor 176 and a resolver stator 178. The resolver rotor 176 is fixed to the impeller hub 172. The resolver stator 178 is fixed to the bell housing 120 via a plate 180. For example, a connector 182, e.g., a bolt, fixes the plate 180 to the bell housing 120, and a connector 184, e.g., a rivet, fixes the resolver stator 178 to the plate 180. The connector 182 is disposed radially outward of the resolver stator 178. The resolver rotor 176 is axially aligned with the resolver stator 178. In other words, a line perpendicular to the axis of rotation AR can be drawn, extending through both the resolver stator 178 and the resolver rotor 176.

[0021] The hybrid module 100 further includes a drive plate assembly 130. The drive plate assembly 130 includes an inner drive plate 132 and an outer drive plate 134 fixed to the inner drive plate 132. The inner drive plate 132 is fixed to the rotor carrier 106 at its radially inner end. Specifically, the inner drive plate 132 is fixed to the rotor carrier 106 via rivets. The inner drive plate 132 is positioned radially inward from the outer surface of the rotor segment 108. The inner drive plate 132 may be fixed to the outer drive plate 134 via a weld 140. In such an example, the weld 140 is positioned radially outward from the rivets and radially inward from the outer surface of the rotor segment 108.

[0022] The outer drive plate 134 extends radially outward from the outer surface of the rotor segment 108. The outer drive plate 134 is fixed to the flex plate 138 of the crankshaft (unnumbered) of a vehicle engine (not shown) via studs 136. That is, the studs 136 transmit torque from the flex plate 138 to the drive plate assembly 130. The studs 136 may be fixed to the outer drive plate 134 at their radially outward ends, for example, via press-fit connections.

[0023] FIG. 2 provides an alternative embodiment of the drive plate assembly 230. In contrast to the drive plate assembly 130 shown in FIG. 1, which includes an inner drive plate 132 welded to an outer drive plate 134, the drive plate assembly 230 includes an inner drive plate 232 fixed to an outer drive plate 234 via a connector 240, e.g., a bolt. In one such example, the connector 140 is disposed radially outside the rivet and radially inside the outer surface of the rotor segment 108. The flex plate 238 may include a window 241 that extends axially therethrough. The window 241 of the flex plate 238 may be radially and circumferentially aligned with the connector 240 such that the connector 240 extends into the window 241. Aligning the window 241 with the connector 240 enables packaging the drive plate assembly 230 within the envelope of the hybrid module 100. That is, disposing the connector 240 within the window 241 can reduce the space required to package the hybrid module 100.

[0024] The embodiments disclosed herein provide a drive plate assembly having an inner drive plate and an outer drive plate fixed to the inner drive plate to expand the space available within a typical hybrid module during magnetization of the rotor segment. By having an outer drive plate and an inner drive plate, the outer drive plate can be fixed to the inner drive plate after magnetization of the rotor segment, which expands the space within the hybrid module for the magnetization tool to magnetize the rotor segment. Additionally, the inner drive plate can be fixed to the rotor carrier via a rivet prior to assembly of the torque converter, which enables fixing the drive plate assembly to the rotor carrier in a manner that prevents fluid from leaking from the rotor carrier. In this way, the hybrid module can be assembled to achieve the desired magnetization of the rotor segment while preventing fluid from leaking from the rotor carrier.

[0025] FIG. 3 is a diagram of an exemplary process 300 for assembling a hybrid module 100 that includes drive plate assemblies 130, 230 having inner drive plates 132, 232 and outer drive plates 134, 234. The process 300 disclosed herein includes exemplary steps that are executed in an exemplary order. However, it should be understood that the process 300 may include fewer steps and / or the steps may be executed in a different order.

[0026] The process 300 begins at block 305. At block 305, for example, the inner drive plates 132, 232 are fixed to the rotor carrier 106 via rivets. The process 300 continues to block 310.

[0027] At block 310, the rotor segment 108 is assembled to the rotor carrier 106. For example, as discussed above, the end rings 110 can be fixed to the rotor carrier 106, such as by welding, to compress the spring end plates 112, 114 that clamp and / or fix the rotor segment 108 to the rotor carrier 106. The process 300 continues to block 315.

[0028] At block 315, the impeller shell 150 of the torque converter 142 is fixed to the rotor carrier 106 via a weld 152. Before fixing the impeller shell 150 to the rotor carrier 106, other components of the torque converter 142, such as the turbine 144, the lock-up clutch 154, the damper 156, etc., can be assembled to the impeller shell 150 and / or the rotor carrier 106. The process 300 continues to block 320.

[0029] In block 320, the rotor segment 108 is magnetized, for example, according to a known rotor magnetization technique. A magnetization tool, such as one known, is positioned radially outward of the rotor segment 108. In this configuration, the inner drive plates 132, 232 are radially separated from the magnetization tool, which increases the available space for positioning the magnetization tool to adequately magnetize the rotor segment 108, which can help achieve the desired performance of the e-motor including the rotor segment 108. The magnetization tool is removed after the rotor segment 108 has been magnetized. Process 300 continues in block 325.

[0030] In block 325, the outer drive plates 134 and 234 are fixed to the inner drive plates 132 and 232. For example, as shown in Figure 1, the outer drive plate 134 may be fixed to the inner drive plate 132 via a weld 140. In another example, as shown in Figure 2, the outer drive plate 234 may be fixed to the inner drive plate 232 via a connector 240, for example, a bolt. Process 300 continues to block 330.

[0031] In block 330, the outer drive plates 134, 234 are secured to the flex plates 138, 238 via studs 136. In the embodiment shown in Figure 2, block 330 may further include aligning the window 241 of the flex plate 238 with the connector 240 before securing the flex plate 238 to the outer drive plate 234, as discussed above. Process 300 ends after block 330.

[0032] While exemplary embodiments have been described above, these embodiments are not intended to describe all possible forms encompassed by the claims. The terms used herein are descriptive, not restrictive, and it should be understood that various modifications can be made without departing from the spirit and scope of this disclosure. As described above, features of various embodiments can be combined to form further embodiments of this disclosure, which may not be expressly described or illustrated. While various embodiments have been described as offering advantages or being preferable to other embodiments or prior art implementations with respect to one or more desired characteristics, those skilled in the art will recognize that one or more features or characteristics can be compromised to achieve desired overall system attributes, depending on the specific application and implementation. These attributes may include, but are not limited to, cost, strength, durability, lifecycle cost, marketability, appearance, packaging, size, maintainability, weight, manufacturability, and ease of assembly. Therefore, insofar as any embodiment is described as being less desirable than other embodiments or prior art implementations with respect to one or more characteristics, these embodiments may not be outside the scope of this disclosure and may be desirable for a particular application. [Explanation of symbols]

[0033] 100 Hybrid Modules 102 Rotor Assembly 104 Stator Assembly 106 Rotor Carrier 108 rotor segments 110 End ring 112 Spring end plate 114 Spring end plate 116 Axial extension 118 Radial extension 120 Bell Housing 122 Stator Carrier 124 stator segments 126 Water Jacket 128 Shield Chamber 130 Drive Plate Assembly 132 Inner drive plate 134 Outer drive plate 136 studs 138 Flex Plate 140 Welded section 142 Torque Converter Assembly 144 Turbine 146 Turbine Shell 148 Impeller 150 Impeller Shell 152 Welded section 154 Lock-up clutch 156 Damper 158 Stator 160 pistons 162 Clutch Plate 164 spring 166 Cover Plate 168 Cover Plate 170 Output section 172 Impeller Hub 174 Resolver Assembly 176 Resolver Rotor 178 Resolver Stator 180 Plate 182 Connector 184 Connector 230 Drive Plate Assembly 232 Inner drive plate 234 Outer drive plate 238 Flex Plate 240 connectors 241 windows AR rotation axis

Claims

1. It is a hybrid module, Rotor carrier and A rotor segment supported by the rotor carrier, A torque converter, wherein the torque converter is An impeller having an impeller shell fixed to the rotor carrier, wherein the impeller shell and the rotor carrier define a housing between them, A turbine having a turbine shell that is in fluid communication with the impeller shell, and a torque converter including the turbine, disposed within the housing, The housing comprises a drive plate assembly disposed on the outside of the housing, and the drive plate assembly is An inner drive plate fixed to the outer surface of the radially extending portion of the rotor carrier located radially inward from the rotor segment, Includes an outer drive plate fixed to the inner drive plate, configured to receive torque, and extending radially outward from the outer surface of the rotor segment, The system further comprises a stud configured to receive the torque, wherein the stud is supported by the outer drive plate and is disposed at its radially outer end, and the outer drive plate is fixed to an inner drive plate radially inward of the stud. Hybrid module.

2. The hybrid module according to claim 1, wherein the inner drive plate is disposed radially inward from the outer surface of the rotor segment.

3. The hybrid module according to claim 1, wherein the outer drive plate is fixed to the inner drive plate radially inward from the outer surface of the rotor segment.

4. The hybrid module according to claim 1, wherein the outer drive plate is fixed to the inner drive plate via a weld.

5. The hybrid module according to claim 4, wherein the welded portion is located radially inward from the outer surface of the rotor segment.

6. The hybrid module according to claim 1, wherein the outer drive plate is fixed to the inner drive plate via a connector.

7. The hybrid module according to claim 6, wherein the connector is located radially inward from the outer surface of the rotor segment.

8. The hybrid module according to claim 6, further comprising a flex plate, wherein the outer drive plate is axially disposed between the rotor segment and the flex plate and is fixed to the flex plate radially outward of the connector.

9. The hybrid module according to claim 8, wherein the flexible plate includes windows aligned radially and circumferentially with respect to the connector, and the connector extends into the windows.

10. The hybrid module according to claim 1, wherein the inner drive plate is fixed to the rotor carrier radially inward of the outer drive plate.

11. The hybrid module according to claim 1, wherein the outer drive plate is fixed to the inner drive plate radially inward of the stud.

12. A method for assembling a drive plate assembly to the hybrid module according to claim 1, wherein the method comprises: The inner drive plate of the drive plate assembly is fixed to the rotor carrier, Attaching the rotor segment to the rotor carrier, The impeller shell of the torque converter is attached to the rotor carrier, After magnetizing the rotor segment, the outer drive plate of the drive plate assembly is fixed to the inner drive plate, Methods that include...

13. The method according to claim 12, wherein the outer drive plate is fixed to the inner drive plate via a weld.

14. The method according to claim 12, wherein the inner drive plate is disposed radially inward from the outer surface of the rotor segment.

15. The method according to claim 14, wherein the outer drive plate extends radially outward from the outer surface of the rotor segment.

16. The outer drive plate is fixed to the inner drive plate via a connector, and the method is Aligning the window in the flex plate with the connector, The flex plate is fixed to the outer drive plate via a stud, The method according to claim 12, further comprising:

17. The method according to claim 12, wherein the outer drive plate is fixed to the inner drive plate radially inward from the outer surface of the rotor segment.

18. The method according to claim 12, further comprising fixing the outer drive plate to the flex plate via a stud.

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